JP2000229367A - Molded panel, its manufacturing method and dismantling method - Google Patents

Abstract

(57) [Problem] To provide a molded panel which can be easily separated and regenerated by using a discarded molded product or the like, a manufacturing method thereof, and a dismantling method. SOLUTION: A pulverized product obtained by pulverizing a resin molded product is mixed with an adhesive to obtain a second layer 4 which is then mixed with a first layer 5.
A molded panel 1 is newly obtained by molding using a precursor laminated to be used as a backing material of a colored ABS resin. Further, the separation process when the molded panel 1 is discarded is achieved by heating to make any one of the first and second layers softened and peeling off from the laminated interface, and is used for recycling. To be offered.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded panel having a design property, a method of manufacturing the same, and a method of dismantling the same, and more particularly to the formation of a multilayer structure having a layer containing a crushed product of discarded resin. .

[0002]

2. Description of the Related Art With regard to various resins used in design materials and structural materials for environmental protection, harmful substances when used resin molded products that are difficult to reuse are disposed of or disposed of by burning. In order to eliminate the possibility of outflow of toxic substances and generation of harmful gases, there is a demand for applications and technologies for effectively utilizing or reusing these resins.

[0003] A separation method for recovering and reusing used resin is as follows. In a refrigerator or an air conditioner, a heat insulating box or a housing portion from which a main component such as a compressor or a heat exchanger is removed is removed by a crusher to a size of about several mm. After being crushed to a size, a magnetic material, mainly iron, is collected by magnetic force, and then metal and resin are separated by a separation method using a difference in specific gravity due to vibration or adsorption by eddy current. In addition, non-ferrous metals separate aluminum and copper by utilizing the difference in specific gravity, and after separating foams by wind power for resins, in some cases, the resins are further floated and sedimented using water etc. The olefins can be recovered by sorting.

Japanese Unexamined Patent Application Publication No. 9-194716 discloses a method for reusing the separated resin, in which a thermoplastic resin used for an inner box or interior material of a refrigerator and urethane foam as a heat insulating material are specified. Melting and mixing at a ratio having a range is described. Further, JP-A-10-151629 discloses that a plurality of types of plastics are agitated by a mixer equipped with a high-speed rotating blade, and the molten mixture is heated by frictional heat. The method of obtaining is described. All of these mixtures have been obtained for the purpose of being applied to other molded articles as they are.

[0005] Therefore, when the resin obtained from such a recovery system is to be reused, an arbitrary pigment is added to the resin mixture, and then the resin mixture is colored. It is shaped into a shape and used again.

[0006]

However, the use of the recycled resin as described above involves adding a large amount of pigment in order to conceal the color originally possessed and obtain a further desired color development. Not only is essential, but also the discoloration accompanying the deterioration of the used resin is taken into consideration, facilitating the fading, and causing a problem that the initial design property is easily damaged.

Further, since the recycled resin is an unspecified mixture of a plurality of resins, it is difficult to always obtain stable characteristics. For example, when a molded product is obtained by using a vacuum molding method, Since it is extremely difficult to control the elongation of the resin in an arbitrary high-temperature atmosphere within a certain range, it is a complicated task to secure the stability of production by always adjusting the temperature and stretching speed. And it will be very difficult.

[0008] Further, when a plurality of used unspecified resins are mixed, there are some combinations having poor compatibility. Therefore, the design surface of the obtained molded product has an uneven stripe pattern or, in some cases, an uneven stripe pattern. Irregularities may even occur due to the generation of voids such as voids.

[0009] On the other hand, when various products using molded products obtained from such materials are collected as used waste and then re-processed, the products are further separated by pulverization and then separated. Since the resin mixture can become a resin mixture, it is more difficult to reuse the resin mixture.

The present invention has been made to solve the above-mentioned problems, and impairs the design property in effectively utilizing a pulverized product such as a resin molded product used for discarded home electric appliances. Means of applying to a molded article as a recycled material without any means and the form of the product, and furthermore, separate the molded article using the recycled material as a recycled material that is easy to use effectively even when it is discarded after re-use is completed. It provides a method.

[0011]

According to a first aspect of the present invention, there is provided a molded panel comprising a first layer positioned on a design surface formed by arbitrarily colored resin, and a first layer formed of the first layer. On the surface on the anti-design surface side, a pulverized product of the resin and a second layer obtained by solidifying the second layer containing a resin component having a lower melting point than the resin component constituting the first layer are integrated in a laminated state. It consists of

[0012] The molded panel according to the second invention of the present invention comprises:
A nonwoven sheet is provided between the first layer and the second layer, the nonwoven sheet holding the fibrous material in a non-linear and disordered orientation.

A molded panel according to a third aspect of the present invention comprises:
The second layer comprises a non-woven sheet comprising the flame retardant fibers on the opposite surface of the first layer in a non-linear, random orientation.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a molded panel, comprising: forming a first layer located on a design surface into a sheet shape; Mixing a resin having a low melting point and a crushed product of the resin to obtain a resin mixture constituting a second layer, and laminating the resin mixture constituting the first layer and the second layer to form a laminated sheet And a step of thermoforming the laminated sheet.

In the method of manufacturing a molded panel according to a fifth aspect of the present invention, in the step of thermoforming, the first layer is formed on the design surface by pressing against a mold using vacuum and pressurized air. Things.

According to a sixth aspect of the present invention, there is provided a method for manufacturing a molded panel, comprising: forming a first layer positioned on a design surface into a sheet; Mixing a resin having a low melting point and a pulverized product of the resin to obtain a resin mixture constituting the second layer; and a resin having a melting point lower than the melting point of the resin constituting the first layer dissolves the fibrous substance. Forming a nonwoven-like sheet that is held in a linear and disordered orientation state, placing the nonwoven-like sheet on the first layer, and further forming the second layer thereon And a step of spraying a resin mixture to obtain a molding precursor, and a step of thermoforming the molding precursor.

[0017] A method of manufacturing a molded panel according to a seventh aspect of the present invention includes a step of forming a first layer located on a design surface into a sheet shape, and a step of forming the first layer and a fibrous substance in a non-linear manner. A step of obtaining a laminated sheet by laminating a nonwoven fabric sheet held in a random orientation state, and mixing a resin having a melting point lower than the melting point of the resin constituting the first layer with a crushed product of the resin. Obtaining a resin mixture constituting the second layer by
A step of spraying a resin mixture constituting the second layer on the nonwoven sheet side of the laminated sheet to obtain a molding precursor; and a step of thermoforming the molding precursor.

According to an eighth aspect of the present invention, in the method for producing a molded panel, in the step of obtaining a molding precursor, a non-woven sheet is further placed on the resin mixture after spraying the resin mixture. It is.

In the method for producing a molded panel according to a ninth aspect of the present invention, in the step of obtaining the resin mixture constituting the second layer, the method comprises the steps of: Is mixed with a resin having a melting point lower than the melting point of the resin constituting the above, and a melting point higher than the melting point of the olefin resin.

The method for dismantling a molded panel according to the tenth aspect of the present invention is characterized in that the molded panel according to the second aspect or the third aspect of the present invention has a temperature lower than the softening temperature of the thermoplastic resin forming the first layer. After heating at a high temperature, the resin is bent to separate the resin.

[0021] A method for dismantling a molded panel according to an eleventh aspect of the present invention comprises:
After heating to a temperature higher than the temperature at which the first layer or the second layer softens, the resin and the non-woven sheet provided between the first layer and the second layer are peeled off, thereby separating the resin. Is what you do.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Embodiments described in the present embodiment relate to claims 1, 4, 5, and 9 of the present invention, and will be described below based on the illustrated embodiments. 1 is a perspective view of the molded panel as viewed from below, FIG. 2 is a conceptual view of a cross section showing the internal structure of the molded article of FIG. 1 cut along AA, and FIG. 3 shows a method of manufacturing the molded panel. It is a manufacturing process drawing.

The structure of the molded panel according to the present invention will be described. The embodiment shown in FIGS. 1 and 2 is a molded panel according to the present invention, which is provided with an air outlet used for a ceiling-embedded type air conditioner. The molded panel 1 is a large-sized molded product having a width and a length of 500 to 1200 mm. Here, FIG. 1 shows a molded panel 1, and the A side 2 is exposed to the interior of the room and needs to secure the design property, while the B side 3 which is the back side is located on the ceiling side, so it is almost used for design. Nothing. Therefore, even if the surface of the B surface 3 has irregularities or uneven color, it is sufficient that the dimensions and shape are maintained and the required strength can be ensured.

This molded product is taken along the line AA in the molded product of FIG.
The details of the internal structure will be described below with reference to FIG. First, the second layer 4 is a resin mixture including a mixture of a crushed resin recovered from various discarded molded products and a thermoplastic resin having a low melting point used for bonding to fix the resin. Is a layer colored with carbon black or the like in accordance with. Next, the first, which has a smooth surface which is uniformly and arbitrarily colored and which secures the design property.
The layer 5 is made of an unused resin and has a thickness to cover the second layer 4 using the resin recovered from the discarded molded product. In other words, the color depth and thickness may be determined according to the color of the second layer 4, and therefore, the second layer 4 is formed of a thin layer of 1 mm or less.

Next, a method of manufacturing a molded panel will be described with reference to a manufacturing process diagram shown in FIG. 3 and a conceptual diagram of a molding device shown in FIG. First, an EVA resin 8 of 20 to 100% by weight based on the crushed material 7 is added to a crushed material 7 mixed with an unspecified type of resin obtained by crushing various types of discarded molded products used for the second layer 4. Then, by stirring and mixing under heating, a composition that can be formed into a sheet is obtained (S-1). At this time, for example, the temperature at the time of stirring and mixing using the extruder 6a is:
110-170 ° C., at which the EVA resin melts, is preferred.
30-150 ° C is particularly preferred. If the crushed material 7
Even if a resin that does not melt under this temperature condition is contained, the particles rub against each other during the mixing and kneading processes in the extruder 6a to eliminate corners, remain as an island structure having a shape close to a sphere, and remain EVA. Since the resin wraps these particles and adheres to each other to obtain an integrated composition, when the laminate with the first layer 5 having the design property later and the laminated sheet are thermoformed, the design property is improved. Damage to the design surface that can be damaged can be suppressed.

Next, the above-mentioned first layer 5 and the second layer 4 to be laminated were formed into a sheet by using a mixture of the above-mentioned pulverized material 7 and a resin having an adhesive function with a low melting point. (S
-2). The discarded resin used here is 2 mm or less, and preferably is crushed and sorted to 0.5 mm or less, and the resin having a low melting point to be used for bonding is smaller than the colored ABS resin forming the first layer 5. Has a low melting point. If the melting point of the resin used for bonding is higher than that of the first layer 5, the second layer 4
When the first layer 5 is pressed at the time of lamination or thermoforming of a sheet in a laminated state, the first portion to be provided on the design surface of the product is hardly deformed. It is not preferable because the layer 5 is deformed and the design of the obtained molded product is deteriorated.

From the above, an EVA resin (ethylene / vinyl acetate copolymer) is preferable as the resin having a low melting point used for the second layer 4, and particularly, a vinyl acetate content of 5 to 7%.
Has a tough property with excellent adhesiveness and flexibility, so that it is firmly laminated and integrated.
Has a softening point of 20 to 4 as compared with the ABS resin used for the layer 5 of
Since the temperature is as low as 0 ° C., even if the discarded resin contains a resin having a high melting point, the second layer 4 can be formed as long as the thermoforming condition for the thermoforming of the ABS resin is maintained. Even when the first layer 5 is pressed, the convex portion which is hard and hardly deforms easily moves and the application of stress can be avoided, so that the occurrence of deformation can be suppressed.

However, when the crushed material 7 contains an olefin resin not to be bonded, it is preferable to exclude as much as possible. If the olefin resin cannot be removed and a large amount of residue is observed, EVA
Excessive injection of the resin or mixing and kneading in a state of being heated to a temperature close to the temperature at which the olefin-based resin melts can be integrated with the other resin and the EVA resin in the pulverized material 7, so that peeling is performed. Defects can be eliminated by making the portion so small that it can be ignored, or by wrapping it with an adhesive resin, so that the sheet shape can be adjusted so as not to impair the appearance in particular. In addition, if the mixture is heated to a temperature close to the temperature condition at which the olefin resin melts, the temperature becomes higher than the melting point of the olefin resin due to friction. That is, the second layer 4 has a melting point lower than the melting point of the resin constituting the first layer 5,
It also mixes with a resin having a melting point higher than that of the olefin resin.

On the other hand, the first layer 5, which is an unused and arbitrarily colored ABS resin, was formed into a sheet (S-3). The sheet material used at this time has a thickness of 1.4 mm obtained by subjecting a normal molded product to coloring using a pigment of 0.5 to 1.5% based on the weight of the uncolored resin. Against
Since the second layer 4 provided for lamination with the first layer 5 has a non-uniform coloring unevenness or a different color), it is necessary to increase the amount of the pigment added while keeping the sheet thickness unchanged. And, in some cases, a thicker molded product than normal.
It is used by increasing the hiding power to 8 mm. In the present embodiment, since the reinforcing effect is obtained by backing the resin composition containing the pulverized resin collected from the various molded products discarded in the later process, the thickness is reduced to 0.5 mm. By doing so, it is possible to achieve both a reduction in the resin used and a reduction in weight.
A darkly colored sheet material was provided using a pigment concentration of 2.5%, which was higher than usual.

Next, a second mixture comprising a kneaded mixture of a pulverized material 7 obtained by pulverizing various molded products using the extruders 6a and 6b shown in FIG.
Layer 4 and the first layer 5 made of unused and optionally colored ABS resin 9 are laminated (S-4), and the extruded sheet 11 is formed.
a and 11b are formed. FIG. 5 shows an extruded sheet 11a, 1
It is a perspective view of T die 10a and 10b which shape 1b.
The extruded sheet 11b obtained by extruding the ABS resin 9 into a sheet from the extruder 6b is adjusted to an arbitrary sheet surface temperature by the first cooling roll 12, and is integrated with the extruded sheet 11a of the compositions 7 and 8. Then, a sheet laminate 15 in which both resin materials are laminated is obtained. Further, the sheet laminate 15
By applying pressure using a pressure roll 13, a second layer in which at least the colored ABS resin surface layer of the sheet laminate 15 is excellent in surface smoothness, while the interlayers can be completely adhered and fused. The cooling roll 14 makes the surface smooth, and excellent design properties can be secured.

At this time, the particles of the unmelted resin pulverized material contained in the second layer 4 are excessively over-absorptive to the ABS resin forming the first layer 5 in a state close to softening and insufficient in hardness. It can be expected that a pattern will be given to the design surface by pressing on the design surface. In such a case, the extruders 6a, 6
The hardness of the first cooling roll 12 after the ABS resin 9 has been discharged from the extruder 6a by exchanging the b and the hardness of the first cooling roll 12 are increased, and the pressing by the pressure roll 13 is reduced. It is important to improve the rigidity of the second layer 4 at the time of lamination, maintain the softened state of the second layer 4, and adjust so as not to hinder the movement of the pulverized material particles when receiving a load. It is also effective to interpose a nonwoven fabric having glass fibers or the like between the first layer 5 and the second layer 4.

The laminate 1 of the sheet thus obtained
No. 5 obtains a laminated sheet 17 having an arbitrary size necessary for forming a formed panel by cutting off the edges using a knife and a shear 16 (S-5).

The laminated sheet 17 obtained in the step (S-5) is subjected to thermoforming (S-6) in which the first layer 5 as a design surface is pressed against a mold by using vacuum and pressurization or a combination thereof.
Thus, a molded panel 1 as a molded product was obtained (S-7).
In the thermoforming, by using the combined vacuum / air / pneumatic molding device 18 shown in FIG. 6, a preliminary stretching is applied to the laminated sheet 17 at a low tensile speed by the compressed air and then pulled at a high speed. Since the laminated sheet 17 is stretched and shaped by the method, it is advantageous in suppressing uneven thickness, which is a remarkable difference in thickness, even if the thickness is large, and in preventing and maintaining the adhesion between the layers. Become.

A specific molding method using the combined vacuum / pneumatic molding device 18 will be described below with reference to the manufacturing process diagram of FIG. First, the laminated sheet is heated to a temperature slightly above the softening point of the second layer (S-11). At this time, the temperature is 140 to 170 ° C., and the E contained in the first layer is
Although the VA resin is used for melting, it is important to use a resin whose content and molecular weight of vinyl acetate are adjusted so as not to flow down. It is also effective to set the mold arrangement in the molding machine so that the first layer is on the upper surface.

Next, air (pressurized air) is sent into the mold 19, and the laminated sheet 17 softened by heating is removed from the mold 19.
After pre-stretching by inflating in the opposite direction to (S-1)
2) The first layer 5 is formed on the surface of the mold 19 by evacuating from the exhaust pipe 20 so that the inside of the mold below the mold 19 is kept in a vacuum state (S-13). It can be close. At the time of molding, if a nonwoven fabric of glass fiber is provided, the behavior of the molded panel 1 is not greatly deformed because the shape of the molded panel 1 does not have a deep drawing structure, and the tensile force exerted in a slight plane direction is not exerted. Since the upper and lower resin layers, particularly the first layer 5, are in a softened state, the fibers do not slip and generate a large repulsive stress.
The molded article can be deformed following the upper and lower layers, adapt well to the resin, and maintain close contact.

At this time, in the step of forming the laminated sheet (S-4), if the application of the pressure using the pressure roll is sufficient, the series of steps (S-11 and S-12) are performed. Although the layers are not separated under the heating state, air (pressurized air) is further fed into the upper box 21 from the air supply pipe 22 in the step (S-13) to apply pressure to the laminated sheet 17. By doing so, the effect of preventing separation between layers can be obtained even more.

Further, the laminated sheet 17 formed in close contact with the mold 19 is deformed by the stress applied at the time of removal by cooling the resin temperature to a temperature at which no deformation occurs (S-14). And at the time of release from the mold (S-15), the first layer 5, which is the design surface, can be smoothly released to secure the gloss of the surface of the molded product. Can be obtained. Finally, trimming (cutting while leaving only necessary parts) (S-16) can obtain a formed panel 1 having a desired shape (S-17).

Formed panel 1 obtained by the above method
In order to effectively utilize and efficiently take in the pulverized resin collected from the discarded molded products, the amount of unused ABS resin that is the first layer 5 should be reduced and used. Is obtained.

Before the molding panel 1 is formed,
Since a composite sheet including a resin pulverized material is provided in advance, ordinary thermoforming can be used as it is, and only the sheet can be formed and stored.

Embodiment 2 Embodiments described in the present embodiment relate to claims 1, 2, 3, 6, 8, and 9 of the present invention. FIG. 8 is a cross-sectional view of a formed panel according to Embodiment 2, and FIG. Manufacturing process diagram showing a panel manufacturing method,
FIG. 11 is an explanatory diagram showing a molding method.

The molded panel of the present invention is a molded panel provided with an air outlet for use in an air conditioner of a recessed ceiling type similar to that of the first embodiment, and has a chamber similar to the shape shown in the perspective view of FIG. A side 2 which is exposed to the inside and requires design, and B side 3 which is located on the ceiling side and maintains the size and shape even if it has irregularities or color unevenness and contributes to securing necessary strength. It has. FIG. 8 is a cross-sectional view of the molded panel 1 of the present invention.
Layer 4 and the first layer 5 and the first layer 5 on the side B 3 containing the mixture of the adhesive and the pulverized resin collected from the discarded molded products. It consists of a nonwoven fabric 27 of glass fiber laminated between the second layers 4 and on the side opposite to the A-side of the second layers. Further, as for the mounting structure of the molded plate to the apparatus main body and the mounting structure of components such as blades, a partially thick portion 24 is provided in the layer on the B side 3 side, or as shown in FIG. What is necessary is just to fix using the component 23 in which the collar part 25 was arranged.

Hereinafter, the manufacturing process will be described with reference to the manufacturing process diagram of the molded panel shown in FIG. 10 and the explanatory diagram showing the molding method shown in FIG. First, a used resin molded product or the like is pulverized using a crusher or the like having a rotary blade to obtain a resin pulverized product (S-21). Then, the resin pulverized product and a thermosetting resin in a semi-cured state are used. Then, a semi-cured epoxy resin that functions as an adhesive is mixed (S-22). Mixing is preferably performed using a mixer or a rotating drum equipped with mixing blades.

The epoxy resin used here maintains a fine powder state in which it becomes a powder at the time of mixing and uniformly adheres to the surface due to static electricity generated by rubbing of the resin pulverized products, and also has a good design. It is preferable that the layer on the side of the A surface 2 to be secured has a low melting point that does not cause deformation, and is a highly active material that cures by heating for a short time. As an example, Table 1 shows the composition of the adhesive used in the present embodiment.

[0044]

[Table 1]

A method for producing an adhesive using the above-described raw materials will be described below. First, after mixing these raw materials uniformly, a thin film is formed on a heat-resistant and flexible sheet such as polyethylene terephthalate or aluminum foil. After spraying, this is dried in a thermostat at 90 ° C. for 10 minutes to remove acetone and advance the reaction. The epoxy resin in a semi-cured state, which is the obtained adhesive, is in a state of being very brittle and can be easily pulverized, so that a fine powder state can be secured at the time of mixing, so it is not necessary to perform pulverization in advance, and It is also possible to use it as it is peeled off.

Next, a sheet 26 which is an unused and arbitrarily colored ABS resin to be a layer on the side A 2 is formed into a sheet shape by extrusion molding or the like (S-23), and then obtained. A glass fiber nonwoven fabric 27, which was impregnated with a separately prepared resin shown in Table 1 and then dried, was placed on the design side surface in FIG.
It is placed in a state as shown in FIG. This glass nonwoven fabric 27 was obtained by immersing a glass fiber nonwoven fabric in the resin liquid shown in Table 1 (S-24), and then performing a drying process (S-25) for 10 minutes in a thermostat at 90 ° C. The obtained sheet has a brittle and semi-hardened epoxy resin adhered to the glass fiber, so that the sheet has a brittle and hard state.

Further, a glass nonwoven fabric 27 impregnated with an epoxy resin is placed on the sheet obtained in (S-23), and a mixture 28 of a crushed resin and a semi-cured epoxy resin is further placed on the glass nonwoven fabric 27 to a thickness of about 5 mm. After laminating (S-26) by spraying to a thickness, the surplus nonwoven fabric 27) is bent at its end as shown in FIG. 11B to form a surrounding molding precursor 29 (S-26). 27). At this time, the surplus semi-cured epoxy resin which does not adhere to the surface of the resin pulverized material due to static electricity generated at the time of mixing is generated. This is preferable because the disassembly of the compound is not impaired.

The molding precursor 29 is heated at 175 ° C. in the state shown in FIG.
After the sheet 26 of the ABS resin, which is to be the layer on the side of the A side 2, is heated to near the heat deformation temperature and placed on the upper surface of the upper surface 0, with the outer periphery fixed 31, as shown in FIG. Lower the mold 32 to 1 to 10 kg / cm ² , preferably ² to 5 k
By applying a pressure of g / cm ² , compression molding (S-28) was performed. By holding for 15 minutes, the epoxy resin as the adhesive is hardened, and the mixture 28 of the crushed resin and the adhesive is solidified. Thereafter, the mold temperature was lowered to preferably 135 ° C. or lower, which is preferably the thermal deformation temperature of the epoxy resin or lower, and more preferably to 95 ° C. or lower, which is the thermal deformation temperature of the ABS resin to be the layer on the A side 2 side. Later, the molded product was taken out (S-29).

Further, since the molded article obtained in the present embodiment was taken out at a mold temperature equal to or lower than the thermal deformation temperature of the epoxy resin, even if it was subjected to the stress associated with taking out from the mold,
The molded product was less likely to be deformed, and when taken out at a mold temperature equal to or lower than the thermal deformation temperature of the ABS resin, excellent gloss could be obtained on the design surface.

As described above, a molded product was formed by using a semi-cured epoxy resin as an adhesive and using a crushed product of resin, which is originally a waste, as a backing of the molded product forming the design surface. A molded product excellent in design, strength, and rigidity was obtained by a simple compression molding.

Further, by arranging the glass fibers on the surface layer, the flame retardancy required for molded panel molded products such as an air conditioner can be imparted without using a flame retardant.
Moreover, since the nonwoven fabric is a nonwoven fabric in which the glass fibers arranged on the surface layer are oriented in a non-direction, even if the fibers have a deformation behavior due to compression or the like, the fibers easily shift and follow the deformation, so that the fibers are broken. No defects occur.

Although the epoxy resin in a semi-cured state is used as the adhesive here, the resin used for forming the layer on the side A 2 which is the design surface is not affected by problems such as dissolution and crazing. As long as the adhesive has no composition, a liquid adhesive may be used, and the same effect can be obtained.

Embodiment 3 This embodiment relates to claims 1, 2, 3, 7, 8, and 9 of the present invention and shows another aspect of the second embodiment. The structure of the molded panel of the present invention is as follows. A molded product having a cross-sectional structure shown in FIG. 8, a design surface having an arbitrarily colored smooth surface to ensure design properties, and an anti-design surface including a mixture of a resin pulverized product and an adhesive. The present invention is different from the second embodiment in that a thermoplastic resin having a melting point lower than that of the resin used for the design surface is used.

Hereinafter, a description will be given based on the manufacturing process diagram of FIG. 12 and the explanatory diagram of the molding method of FIG. 11 of the second embodiment.
First, a resin molded article obtained by pulverizing a used resin molded product using a crusher or the like is obtained as resin particles (S-31). After that, a resin having a lower melting point than the resin used for the design surface is provided. The resin powder functioning as an adhesive is mixed using a mixer or a rotating drum equipped with mixing blades (S-3).
2).

EVA resin (ethylene / vinyl acetate copolymer) is preferable as the low melting point resin functioning as an adhesive used here, and those having a vinyl acetate content of 5 to 7% are excellent in adhesiveness. Since it has a tough property with flexibility, it is firmly laminated and integrated, and has a melting point and melt viscosity sufficiently lower than those of the ABS resin used for the first layer 5 which is a design surface. Even if hard particles that do not melt are included in the pulverized material obtained by mixing a plurality of kinds of resins, the second layer 4 is hard and deformed when the first layer 5 is pressed. Since the difficult-to-be-convex portion easily moves to avoid applying stress, deformation of the design surface can be suppressed.

Next, an arbitrary colored ABS resin A
After the sheet 26 to be the layer on the side 2 is formed into a sheet by extrusion or the like (S-33), a nonwoven fabric 27 of glass fiber is shown on the anti-design side surface in FIG. It is placed and laminated in such a state (S-34). further,
On the mounted glass nonwoven fabric 27, a resin pulverized material and EVA
The mixture 28 of the resin powder is sprayed to a thickness of about 5 mm (S-3).
5) At this time, the excess EVA resin powder which does not adhere to the surface of the resin pulverized material due to the static electricity generated at the time of mixing is generated. This is also sprayed directly on the glass non-woven fabric 27, especially by impregnating the glass non-woven fabric 27. Thus, it is possible to contribute to the improvement of the reinforcing effect in the molded article, which is preferable. Thereafter, the surplus glass nonwoven fabric 27 was bent as shown in FIG. 9B to obtain a molding precursor 29 (S-36).

As shown in FIG. 11 (c), the molding precursor 29 is placed on the upper surface of the lower mold 30 for compression molding heated to 50 ° C. with the outer peripheral fixing portion 31 fixed thereto, and then is placed 160
The upper mold 32 heated to 0 ° C. is held in a lightly abutting state of 0.1 kg / cm ² or less, and the first layer 5 located on the design surface is held.
By heating the ABS resin sheet 26 to a temperature close to the heat deformation temperature (S-37), a state in which deformation starts to occur is obtained, and then, as shown in FIG.
/ Cm ² , preferably 2 to 5 kg / cm ² , and the upper mold 32 was lowered to perform compression molding (S38). After that, after the mold temperature is lowered to 95 ° C. or lower, which is preferably the heat deformation temperature of the ABS resin to be the first layer 5, more preferably to around 50 ° C. at which the second layer 4 is sufficiently solidified. Then, the molded product was taken out (S-38).

Further, the molded product obtained in this embodiment is
Since the mold was taken out at a mold temperature equal to or lower than the thermal deformation temperature of the EVA resin, it is difficult for the molded product to be deformed by the stress related to the removal from the mold, and the mold temperature is sufficiently lower than the heat deformation temperature of the ABS resin. Therefore, it was possible to obtain excellent gloss on the design surface.

As described above, since the mixture of the EVA resin as the adhesive and the various pulverized resin products was sprayed on the resin sheet forming the design surface, thermoforming was performed, so that the glass fibers were impregnated with the EVA resin. At the same time, it was possible to secure an aspect for adhesion to the ABS resin surface, and it was possible to easily obtain a molding. Furthermore, since a molded product using the mixture as a backing was formed, a molded product having excellent design properties such as excellent gloss and mechanical properties excellent in strength, rigidity and the like was obtained.

Further, since the glass fibers were arranged and held on the surface layer, the flame retardancy required for a molded panel molded product such as an air conditioner could be imparted without using a flame retardant.

Although the EVA resin is used as the adhesive in this case, if the material forming the layer on the side A 2 which is the design surface in FIG. An adhesive having a melting point may be used, and the same effect can be obtained.

Embodiment 4 This embodiment relates to claim 10 of the present invention, and is lining using an adhesive having a higher softening point than the resin material of the first layer which is the design surface obtained in Embodiment 2. This is a disassembly method for the purpose of separating when a molded article provided with a material has been used and provided as waste, and shows a method of peeling a first layer 5 and a second layer 4 shown in FIG. This will be described below based on the process drawings.

Here, the molded product obtained in Embodiment 2 to be dismantled is obtained by mixing a crushed resin such as a discarded resin molded product with a semi-cured epoxy resin as an adhesive in a second layer. No. 4 is used for backing molded products, and since this epoxy resin is completely cured by heating at the time of molding, it has a higher softening point than the ABS resin forming the first layer, and has good design and strength. It is a molded article having particularly excellent rigidity.

For disassembly, first, it is heated to 110 to 140 ° C., which slightly exceeds the softening temperature of the first layer 5 which is the ABS resin forming the design surface of the molded panel obtained in the second embodiment (S-41). ). In this state, the resin pulverized material of most of the waste molded products is in a softened state, whereas the epoxy resin remains in a rigid state.

Next, as shown in the conceptual diagram of FIG.
It is moved by applying pressure using a cylindrical rotary tool such as (S-42). At this time, the second material
Layer 4 is held by an epoxy resin, which is an adhesive maintaining high rigidity, so that the curvature between the two layers acts differently, and a shear force is generated at the interface, causing breakage at the interface. Peeling occurs. Impulsive vibration is applied to this (S
-43), the layer 4 composed of the mixture of the ABS resin forming the design surface, the crushed resin and the epoxy resin positioned on the anti-design surface, and the nonwoven fabric 27 of glass fiber can be separated.

Further, A which forms a design surface after cooling
When the layer 4 located on the anti-design surface separated from the BS resin 5 is subjected to shocking vibration or finely bent, the glass fiber non-woven fabric to which the epoxy resin is arbitrarily attached is peeled off (S-44). ). For the design side, A
Almost all of the backing material can be removed by lightly rubbing with a spatula or the like that does not cause dents on the design surface of the BS resin layer. With respect to the remaining mixed resin composition, the separated materials are rubbed together using a simple blade-shaped stirrer (S4).
5) In a state in which an epoxy resin is arbitrarily adhered, but can be used for backing a molded product using the same means as in Embodiments 2 and 3, such as a resin pulverized product is easily pulverized. Obtained (S-46).

As described above, separation of each layer and each resin is achieved, but the anti-design surface of the molded article to be dismantled is not solidified using a large amount of epoxy resin as an adhesive. Therefore, the peeling and the recovery as a pulverized state are performed by relatively small stress, and by heating to the softening temperature of the ABS resin located on the design surface, it was used to compose the design surface. The thermoplastic resin can be easily peeled off.

Further, since the epoxy resin used for the adhesive is hardly attached to the ABS resin located on the design surface separated by the above method, it can be easily diverted to other uses. Further, since the resin composition used for the anti-design surface could be easily pulverized to an appropriate size, it can be reused, and similarly, it can be easily diverted to other uses.

Further, by forming the mixed composition of the crushed resin and the epoxy resin used as the adhesive by wrapping it in a nonwoven fabric of glass fiber, the resin layer can be reliably removed from the ABS resin positioned on the design surface when peeled off. In addition, it can be peeled off without being scattered, and can contribute to improvement of flame retardancy in the surface layer. If the component does not require flame retardancy, especially if it is a small molded product, the same means can be achieved by disposing a glass fiber non-woven fabric only between the surface layer and the anti-design surface layer. It is possible to Further, in the present embodiment, the nonwoven fabric of glass fiber is used for the interlayer sheet to be peeled, but the nonwoven fabric is not changed to a cloth material, and the use of glass fiber for other fibrous substances is not prevented.

Embodiment 5 FIG. The present embodiment relates to claim 11 of the present invention, and relates to a disposal method in which the molded article obtained in Embodiment 3 has been used and is provided as waste, wherein It dismantles and separates both layers of the anti-design surface. Hereinafter, the sorting method will be described with reference to the process chart of FIG.

The disassembly aims at reusing the resin composition constituting each layer, and easily separates both the design surface and the anti-design surface. Therefore, it is important that each layer does not substantially contain the material of the other layer, and therefore, the following means are used. First, the EVA resin contained in the second layer 4 is softened by heating the molded panel obtained in Embodiment 3 (S-51). Due to this softening, the adhesive strength between the layers of the EVA resin is sharply reduced, so that the EVA resin can be easily peeled off and deformed unless excessive stress is applied to the ABS resin located on the design surface. There is no. The temperature at this time is 70 to 90 ° C., which is slightly higher than the softening point of the EVA resin because the softening temperature of the ABS resin located on the design surface is 100 to 110 ° C.
And preferably around 80 ° C.

With respect to the peeling of both layers, there is a method of peeling off by using a tool such as a spatula, but the second layer is formed on the ABS resin layer which is the first layer 5 located on the design surface. The mixture 28 of the resin pulverized material and the EVA resin powder, which is the layer 4, easily remains, which is not preferable. In the present invention, as in the method shown in FIG. 16, the glass fiber nonwoven fabric 27 disposed between both layers is lifted (S-52), and is preferably disposed at an angle of 90 degrees or less with the ABS resin layer 4. After being folded from the setting direction (S-53), it is peeled off by slowly pulling it together with the mixed composition 4 of the crushed resin and the EVA resin as the backing material from the used molded product (S-5).
4). According to this means, the behavior of peeling the two layers can be imparted stably over a wide area, so that an excessive stress is not locally applied to the design surface made of the ABS resin. , So it can be used again. Furthermore, if the glass fiber nonwoven fabric 27 is peeled off from the backing material (S-55), the resin mixture 28 can be recovered (S-56).

According to the disassembly of the decorative shaped panel by the method as described above, the remaining of the materials constituting the layers facing each other can be extremely suppressed, so that the panels can be reused. Will be possible. In other words, the ABS resin layer forming the design surface recovered by the present method can be recovered almost without adhering the resin on the anti-design surface such as EVA resin. Can also be obtained again. EVA and pulverized resin of used moldings in the layer located on one anti-design surface
As for the resin mixture composition, since it is deformed by tensile stress at the time of peeling, it is difficult to reuse the same shape as it is, but it is pulverized to an appropriate size and as a similar backing material, again It is possible to use for.

Furthermore, it is also effective to use a method of enlarging the peeled surface by enclosing the compressed air in the gap formed by slightly lifting the edge and peeling.

Further, since the mixed composition of the ground resin and the EVA resin is formed by enclosing the nonwoven fabric of glass fiber, the mixed composition is heated to a temperature near the softening point. In a state where it can be easily peeled off and only the mixed composition can be recovered without leaving the nonwoven fabric,
It could be peeled off without fail. At this time, if the size of one side of the molded product is a small molded product of about several tens cm,
The same means can be achieved by disposing a nonwoven fabric of glass fiber only between the surface layer and the layer on the anti-design surface.

The thermal deformation temperature of the EVA resin used is
For example, when the air conditioner is used in a heated state, if the strength required as a design surface is increased to such an extent that it is difficult to develop, if the amount of vinyl acetate contained in the EVA resin is reduced, In addition, the ABS resin used for the design surface is improved in acrylonitrile content to improve heat resistance, or is used in place of another type of resin or design steel sheet, and is used in a high heat deformation temperature. It is not limited to the type of resin used here. Furthermore, in the present embodiment, the nonwoven fabric of glass fiber is used to wrap the layer on the anti-design side in the interlayer sheet to be peeled, but a sheet for imparting flame retardancy in the upper layer of the anti-design side is used. At least, it does not prevent using a nonwoven fabric as a cloth and glass fibers as other fibers.

As described above, in the embodiment of the present invention, the structure of the molded panel molded product and the molding method thereof have been described.
The present invention is not limited to this. For example, conventional panels such as panels such as building materials and structural materials, means using a crushed waste resin molded product in the middle as a lightweight and highly rigid plate material structure, etc. It is also possible to use the structure in a substitute for the application, and various modifications can be made without departing from the gist of the invention.

[0078]

The molded panel according to the first invention of the present invention comprises a first layer formed on a design surface by shaping an arbitrarily colored resin, and a side opposite to the design surface of the first layer. And a second layer obtained by solidifying a pulverized product of the resin and a second layer containing a resin component having a melting point lower than that of the resin component constituting the first layer and solidifying it. Therefore, even if a discarded resin that is uneven and indefinitely colored is used, it is possible to back up the molded product forming the first layer without deteriorating the design property of the design surface. Available to

The molded panel according to the second invention of the present invention comprises:
Since the nonwoven fabric sheet is provided between the first layer and the second layer and holds the fibrous substance in a non-linear and disordered orientation state, the design surface is included in the second layer. Since it is not easily deformed by particles, a smooth and beautiful surface can be secured.

The molded panel according to the third aspect of the present invention comprises:
Since the second layer is provided with a non-woven sheet formed by holding the flame-retardant fibers in a non-linear and disordered orientation on the surface opposite to the first layer, the deformation behavior due to compression or the like is reduced. Even if it has, since the fiber easily shifts and follows the deformation, the flame retardancy can be improved without causing a defect such as breakage.

In the method for manufacturing a molded panel according to the fourth invention of the present invention, the step of forming the first layer located on the design surface into a sheet-like shape and the step of forming the first layer at a temperature lower than the melting point of the resin constituting the first layer Mixing a resin having a low melting point and a crushed product of the resin to obtain a resin mixture constituting a second layer, and laminating the resin mixture constituting the first layer and the second layer to form a laminated sheet And the step of thermoforming the laminated sheet, the resin is discarded by the rigidity and coloring of the resin discarded in the second layer located on the design surface, and thus is affected by deformation and color transfer. Since it is possible to obtain a molded product without the need, and because it is equipped with a complexed sheet containing resin pulverized material in advance,
Normal thermoforming can be used as it is, and only the sheet can be made and stored.

In a method of manufacturing a molded panel according to a fifth aspect of the present invention, in a step of performing thermoforming, a first layer is formed on a design surface by pressing against a mold using vacuum and pressurized air. Therefore, it is possible to prevent the pulverized material or a layer containing the pulverized material from being released by providing the pulverized material, and to provide a rigid backing material.

In the method for manufacturing a molded panel according to the sixth aspect of the present invention, the step of forming the first layer located on the design surface into a sheet-like shape may be carried out based on the melting point of the resin constituting the first layer. Mixing a resin having a low melting point and a pulverized product of the resin to obtain a resin mixture constituting the second layer; and a resin having a melting point lower than the melting point of the resin constituting the first layer dissolves the fibrous substance. Forming a nonwoven-like sheet that is held in a linear and disordered orientation state, placing the nonwoven-like sheet on the first layer, and further forming the second layer thereon A step of obtaining a molding precursor by spraying a resin mixture to be formed, and a step of thermoforming the molding precursor, so that good molding conditions are imparted without excessively softening the design surface. Can be used to improve the design It is possible to ensure that does not lead to lower.

The method of manufacturing a molded panel according to the seventh invention of the present invention comprises the steps of: forming a first layer located on a design surface into a sheet; and forming the first layer and a fibrous material in a non-linear and A step of obtaining a laminated sheet by laminating a nonwoven fabric sheet held in a random orientation state, and mixing a resin having a melting point lower than the melting point of the resin constituting the first layer with a crushed product of the resin. Obtaining a resin mixture constituting the second layer by
A step of spraying a resin mixture constituting the second layer on the nonwoven sheet side of the laminated sheet to obtain a molding precursor, and a step of thermoforming the molding precursor. Therefore, it can be easily molded, and can impart design properties such as excellent gloss and mechanical properties excellent in strength, rigidity and the like.

In the method for producing a molded panel according to the eighth invention of the present invention, in the step of obtaining a molding precursor, after the resin mixture is sprayed, a nonwoven sheet is further placed on the resin mixture. Therefore, the flame retardancy required for a molded panel molded product such as an air conditioner can be imparted without using a flame retardant.

In the method for producing a molded panel according to the ninth aspect of the present invention, in the step of obtaining the resin mixture constituting the second layer, when the pulverized resin contains an olefin-based resin, Is mixed with a resin having a melting point lower than the melting point of the resin constituting the above, and can be integrated with the other resin and the EVA resin in the pulverized material since the resin is mixed with a resin having a melting point higher than the melting point of the olefin resin. Therefore, it is possible to eliminate the defective part by making the peeled part small enough to be ignored, or by wrapping it with an adhesive resin,
Among the sheet shapes, adjustment can be made so as not to impair the appearance.

The disassembly method of the molded panel according to the tenth aspect of the present invention is characterized in that the molded panel according to the second aspect or the third aspect of the present invention has a temperature lower than the softening temperature of the thermoplastic resin forming the first layer. After heating at a high temperature, the resin is separated by bending, so that each composition can be easily and simply peeled off, so that a molded member that can be reused can be collected.

A method for dismantling a molded panel according to an eleventh aspect of the present invention includes the steps of:
After heating to a temperature higher than the temperature at which the first layer or the second layer softens, the resin and the non-woven sheet provided between the first layer and the second layer are peeled off, thereby separating the resin. Since the peeling can be performed without damaging the design surface, the molded member that can be used again can be collected.

[Brief description of the drawings]

FIG. 1 is a perspective view of a molded panel according to a first embodiment of the present invention.

FIG. 2 is a sectional view taken along line AA of FIG.

FIG. 3 is a process chart illustrating a method for manufacturing a molded panel according to the first embodiment of the present invention.

FIG. 4 is a conceptual diagram of a molding apparatus used to mold a resin sheet according to a molded panel according to the first embodiment of the present invention.

FIG. 5 is a perspective view showing a shape of a T-die of the extruder shown in FIG.

FIG. 6 is a conceptual diagram of a press-and-pneumatic forming apparatus for performing thermoforming according to Embodiment 1 of the present invention for manufacturing a formed panel.

FIG. 7 is a process drawing of a designable shaped panel using the molding apparatus of FIG. 6;

FIG. 8 is a sectional view of a molded panel according to the second embodiment of the present invention.

FIG. 9 is a process chart illustrating a method for manufacturing a molded panel according to the second embodiment of the present invention.

FIG. 10 is a cross-sectional view illustrating a method of arranging a flange portion provided on a molded panel according to a second embodiment of the present invention.

FIG. 11 is an explanatory diagram of a molding method according to Embodiment 2 of the present invention, in which a glass fiber mat as a fibrous material of a molded panel is provided.

FIG. 12 is a process chart illustrating a method of manufacturing a molded panel according to the third embodiment of the present invention.

FIG. 13 is a process chart showing a method for dismantling a molded panel according to Embodiment 4 of the present invention.

FIG. 14 is an explanatory diagram of a method for dismantling a molded panel according to Embodiment 4 of the present invention.

FIG. 15 is a process chart showing a method for dismantling a molded panel according to Embodiment 5 of the present invention.

FIG. 16 is an explanatory diagram of a method for dismantling a molded panel according to Embodiment 5 of the present invention.

[Explanation of symbols]

REFERENCE SIGNS LIST 1 molded panel, 4 second layer, 5 first layer, 7 ground resin, 8 low melting point resin (EVA resin), 9 colored resin, 17 laminated sheet, 18 combined vacuum / pressure air molding machine, 27 Glass fiber non-woven fabric, 28 resin mixture, 29 molding precursor, 30, 32 mold.

Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat II (Reference) B29K 63:00 309: 08 B29L 31:10 F term (Reference) 4F100 AK01A AK01B AK03 AK69 AK74 AL05B BA03 BA04 BA07 BA10A BA10B BA10D BA26 DE01B DG01C DG15C DG15D EH20 EH202 EJ24 EJ242 GB07 HB00A JA04B JA20C JA20D JJ07D JL05 JL10A JL16 YY00B 4F208 AA50 AC03 AC04 AG01 AG03 AH25 MA01 MA02 MB01 MB22 MG04

Claims (11)

[Claims] 1. A first layer positioned on a design surface by shaping an arbitrarily colored resin, and a pulverized resin material is placed on a surface of the first layer on a side opposite to the design surface by a first layer. A molded panel comprising: a solidified second layer containing a resin component having a lower melting point than the resin component constituting the layer; 2. A nonwoven fabric sheet comprising a fibrous substance held in a non-linear and disordered orientation state between a first layer and a second layer. Molded panel. 3. The non-woven sheet of claim 2, wherein the second layer comprises a non-woven sheet on the surface opposite to the first layer, the non-woven sheet holding the flame-retardant fibers in a non-linear and disordered orientation. Item 2. A molded panel according to Item 1. 4. A step of forming a first layer located on the design surface into a sheet, and mixing a resin having a melting point lower than the melting point of the resin constituting the first layer with a pulverized product of the resin. A step of obtaining a resin mixture constituting the second layer, a step of laminating the first layer and the resin mixture constituting the second layer to obtain a laminated sheet, and a step of thermoforming the laminated sheet. A method for manufacturing a molded panel, comprising: 5. The manufacturing of a molded panel according to claim 4, wherein in the step of thermoforming, the first layer is formed on the design surface by being pressed against a mold using vacuum and pressurized air. Method. 6. A step of forming a first layer located on a design surface into a sheet, and mixing a resin having a melting point lower than a melting point of a resin constituting the first layer with a pulverized product of the resin. A step of obtaining a resin mixture constituting the second layer; and a non-woven fabric formed by holding a fibrous substance in a non-linear and disordered orientation state with a resin having a melting point lower than the melting point of the resin constituting the first layer. Forming a sheet; placing the non-woven sheet on the first layer; and dispersing a resin mixture constituting the second layer on the sheet to obtain a forming precursor. And a step of thermoforming the molding precursor. 7. A step of forming the first layer located on the design surface into a sheet, and a non-woven sheet formed by holding the first layer and the fibrous substance in a non-linear and disordered orientation. Laminating a resin to form a laminated sheet; and mixing a resin having a melting point lower than the melting point of the resin constituting the first layer and a crushed product of the resin to obtain a resin mixture constituting the second layer. A step of spraying a resin mixture constituting the second layer on the nonwoven sheet side of the laminated sheet to obtain a molding precursor; and a step of thermoforming the molding precursor. A method of manufacturing a molded panel. 8. The molding according to claim 6, wherein in the step of obtaining a molding precursor, a non-woven sheet is further placed on the resin mixture after the resin mixture is sprayed. Panel manufacturing method. 9. In a step of obtaining a resin mixture constituting the second layer, when an olefin resin is contained in the ground resin, the melting point is lower than the melting point of the resin constituting the first layer. 9. The method of manufacturing a molded panel according to claim 4, further comprising mixing with a resin having a melting point higher than the melting point of the olefin resin. 10. Molding in which the molded panel according to claim 2 or 3 is heated at a temperature higher than the softening temperature of the thermoplastic resin forming the first layer and then bent to separate the resin. Panel dismantling method. 11. A nonwoven fabric provided between a first layer and a second layer after heating the molded panel according to claim 3 to a temperature higher than a temperature at which the first layer or the second layer softens. A method for disassembling a molded panel in which resin is separated by peeling off a sheet including a sheet.